What are automated water jetting systems?

Automated water jetting systems are advanced industrial cleaning solutions that combine high-pressure water technology with robotic or programmable control systems. These systems consist of robotic manipulators, sophisticated control interfaces, and high-pressure pumps operating between 500 to 3000 bar (7,250 to 43,500 PSI). Unlike manual operations where operators directly handle equipment, automated systems enable remote operation, ensuring consistent cleaning patterns while keeping personnel safely away from hazardous environments in petrochemical plants, marine vessels, and manufacturing facilities.

What exactly are automated water jetting systems?

Automated water jetting systems represent a significant evolution in industrial cleaning technology, transforming how companies approach surface cleaning and preparation tasks. At their core, these systems integrate three main components: robotic manipulators that handle the water jet nozzles, programmable control systems that direct operations, and high-pressure pumps that generate the necessary water pressure for effective cleaning.

The robotic manipulators serve as the mechanical arms of the system, precisely positioning and moving water jet nozzles according to programmed patterns. These manipulators can be track-mounted, rail-guided, or even magnetically attached to surfaces, allowing them to navigate complex industrial geometries. The control systems act as the brain, coordinating movements, adjusting pressure levels, and monitoring safety parameters throughout the cleaning process.

What sets automated systems apart from manual operations is the removal of direct human contact with high-pressure equipment. While manual water jetting requires operators to physically handle lances or guns under extreme pressure conditions, automated systems allow technicians to control operations from safe distances, often from enclosed control rooms or remote stations. This fundamental difference transforms not just safety protocols but also operational efficiency and consistency.

These systems find extensive application across various industrial sectors. In petrochemical facilities, they clean heat exchangers, storage tanks, and process vessels. Marine applications include hull cleaning, tank maintenance, and deck preparation. Manufacturing plants utilise them for removing coatings, preparing surfaces for inspection, and maintaining production equipment. The versatility of automated water jetting makes it an invaluable tool for maintaining industrial infrastructure while meeting increasingly stringent safety and environmental standards.

How do automated water jetting systems work?

The operational process of automated water jetting systems begins with programmable control systems that serve as the command centre for all cleaning activities. These sophisticated interfaces allow operators to input specific cleaning parameters, including pressure settings, nozzle movement patterns, and coverage areas. Modern systems incorporate touchscreen controls and intuitive software that can store multiple cleaning programmes for different applications.

Sensor integration plays a vital role in ensuring precise and safe operation. Position sensors track the exact location of cleaning heads, while pressure sensors monitor water flow to maintain consistent cleaning power. Some advanced systems include vision systems or laser scanners that map surfaces before cleaning, automatically adjusting patterns to match surface contours. These sensors feed real-time data back to the control system, enabling dynamic adjustments during operation.

The heart of any water jetting system lies in its high-pressure pump capabilities. Operating within the range of 500 to 3000 bar (7,250 to 43,500 PSI), these pumps deliver water at flow rates specifically calibrated for different cleaning tasks. Lower pressures around 500 to 1000 bar (7,250 to 14,500 PSI) work well for removing light deposits and coatings, while pressures approaching 3000 bar (43,500 PSI) tackle the most stubborn industrial scale and hardened materials.

Remote operation capabilities transform how technicians interact with these powerful systems. Operators can control equipment from distances exceeding 100 metres (328 feet), using wireless controllers or fixed control stations. This distance control ensures personnel remain outside danger zones while maintaining full visibility of cleaning operations through cameras or direct sight lines. The automation ensures consistent cleaning patterns by eliminating variables like operator fatigue or inconsistent hand movements, resulting in uniform surface preparation across entire work areas.

What’s the difference between manual and automated water jetting?

The most significant distinction between manual and automated water jetting lies in operator safety. Manual operations expose workers to multiple hazards including high-pressure water streams, flying debris, and the physical strain of handling heavy equipment. Automated systems eliminate these direct exposures by allowing remote operation, reducing workplace incidents and protecting personnel from the inherent dangers of high-pressure water technology.

Consistency of results marks another fundamental difference between the two approaches. Manual water jetting quality depends heavily on operator skill, experience, and physical condition. Factors like fatigue, varying hand pressure, and inconsistent movement speeds can create uneven cleaning patterns. Automated systems deliver programmed, repeatable movements that ensure uniform surface treatment regardless of shift changes or operator variations.

Productivity rates show dramatic improvements with automation. While manual operators typically require frequent breaks due to the physical demands of handling high-pressure equipment, automated systems can operate continuously for extended periods. This capability enables true 24/7 operation in facilities requiring round-the-clock maintenance schedules. A single automated system can often accomplish the work of multiple manual operators while maintaining consistent quality standards.

Operational costs present an interesting comparison between manual and automated approaches. While automated systems require higher initial capital investment, they often deliver superior returns through reduced labour costs, fewer safety incidents, and increased productivity. The ability to operate in challenging industrial settings, such as confined spaces or hazardous atmospheres, further expands the economic advantages of automation by eliminating the need for extensive safety equipment and procedures required for manual operations.

Why are automated systems becoming more important for industrial cleaning?

Stricter safety regulations across global markets drive the increasing adoption of automated water jetting systems. Regulatory bodies worldwide continuously update workplace safety standards, particularly regarding exposure to high-pressure equipment and hazardous environments. Automated systems provide documented compliance with these evolving regulations, offering traceable cleaning records and eliminating direct worker exposure to dangerous conditions.

Labour shortages in skilled industrial trades create additional pressure for automation adoption. Finding and retaining qualified water jetting operators becomes increasingly challenging as experienced workers retire and fewer young professionals enter industrial maintenance fields. Automated systems reduce dependency on specialised manual skills while enabling existing staff to operate multiple systems simultaneously from safe control stations.

The demand for consistent quality standards in industrial maintenance pushes companies toward automated solutions. Industries like aerospace, pharmaceutical manufacturing, and food processing require documented, repeatable cleaning processes that meet strict quality assurance protocols. Automated systems provide digital records of every cleaning operation, including pressure settings, coverage patterns, and completion times, creating comprehensive audit trails for regulatory compliance.

Multi-regional compliance requirements add complexity to international operations that automation helps address. Companies operating across different countries face varying safety standards, environmental regulations, and reporting requirements. Automated water jetting systems can be programmed to meet specific regional standards while maintaining consistent operational procedures. This standardisation simplifies training, reduces compliance risks, and ensures uniform cleaning quality across global facilities. The ability to document and verify cleaning processes becomes particularly valuable when demonstrating compliance to international auditors or certification bodies.

How can DERC Salotech help with your automated water jetting needs?

Our innovative solutions in automated water jetting include the Flexa-Jet Chain Manipulator and MagTrack robotic system, both engineered to address specific challenges in industrial cleaning applications. The Flexa-Jet Chain Manipulator excels in cleaning complex geometries like tube bundles and heat exchangers, using flexible chain technology to navigate tight spaces while maintaining consistent water pressure. The MagTrack system utilises magnetic adhesion to traverse vertical and overhead surfaces, bringing automation capabilities to previously inaccessible areas like ship hulls and storage tank walls.

With over 40 years of expertise in high-pressure water jetting technology, we understand the unique requirements of different industrial sectors. Our engineering team develops customised automation solutions that integrate seamlessly with existing operations, whether you’re maintaining petrochemical facilities, preparing marine surfaces, or cleaning manufacturing equipment. Each system undergoes rigorous testing at our Netherlands headquarters, ensuring it meets both metric and SAE standards for global deployment.

Our global support network spanning 55 countries means you’re never far from expert assistance. We provide comprehensive project support from initial consultation through installation and ongoing maintenance. Our team helps navigate international compliance requirements, ensuring your automated systems meet local regulations while maintaining operational efficiency. This worldwide presence enables us to share best practices and innovations across different markets, bringing proven solutions to your specific challenges.

Beyond equipment supply, we offer comprehensive training programmes through DERC Adviesgroep, our dedicated training subsidiary. These certified courses cover safe operation, maintenance procedures, and advanced programming techniques for automated systems. By investing in operator education, we help you maximise the return on your automation investment while maintaining the highest safety standards. Whether you’re upgrading existing manual operations or implementing completely new automated solutions, our combination of innovative technology, global expertise, and comprehensive support ensures successful project outcomes. Explore our complete range of automated water jetting products to find the perfect solution for your industrial cleaning needs.